Non-flammable aerosol multiuse invert emulsion lubricant

ABSTRACT

Stable water-in-oil emulsions suitable for use as fire-resistant aerosol multipurpose lubricants. The water-in-oil emulsion comprises a synthetic ester base oil, compatible invert emulsifier, water, and a preservative. The aerosol apparatus employs a larger than standard stem orifice to produce a non-flammable aerosol.

CROSS-REFERENCE TO RELATED APPLICATIONS

Priority is claimed on Provisional U.S. Provisional Patent Application No. 62/482,305, filed Apr. 6, 2017, and U.S. Provisional Patent Application No. 62/623,610, filed Jan. 30, 2018, which are incorporated herein in their entirety by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

REFERENCE TO A “SEQUENCE LISTING”, A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON COMPACT DISC

Not Applicable

BACKGROUND OF THE INVENTION 1. Field of The Invention

The present invention relates to non-flammable multiuse aerosol lubricants.

2. Description of Prior Art Including Information Disclosed Under 37 CRF 1.97 and 1.98

This invention relates to an improved aerosol non-flammable composition in the form of a substantially stable water-in-oil emulsion for use in protecting metal from rust and corrosion, penetrating stuck parts, displacing moisture and lubricating almost anything. More particularly, such improved aerosol non-flammable composition consists of water, an oil base, an invert emulsifier, and a preservative. The aerosol delivery system consists of a standard aerosol mechanism with increased stem orifice radius sufficient to create larger than standard droplets in the aerosol to reduce the flammability profile of the aerosol mist.

Multiuse aerosol lubricants are widely known. Generally, such compositions employ hydrocarbons and are flammable. The most widely known and successful of these compounds is marketed under the trademark WD-40®. For over 50 years, consumers have used WD-40® Multi-Use Product (hereinafter WD-40®) to protect metal from rust and corrosion and for penetrating lubrication. WD-40® protects and lubricates effectively, in part, because it so effectively displaces water. The formulation for WD-40® is a trade secret but is generally understood to consist of hydrocarbons and other proprietary ingredients. It does not contain water.

There has long been a need for non-flammable multiuse aerosol lubricants. However, there is an inherent tension between performance and non-flammability in multiuse aerosol lubricants. While hydrocarbons impart much of the performance in multiuse lubricants like WD-40®, they are inherently flammable. Additionally, aerosols add to the danger of creating a flammable product. Conversely, while water decreases the flammability profile of the product, water causes rust and corrosion, which is exactly what multiuse aerosol lubricants are designed to prevent.

The use of water-in-oil emulsions has been used in other fields to create non-flammable lubricants. For example, in the hydraulic field, invert emulsions are routinely used to create non-flammable hydraulic fluids that have lubricating properties. However, because of the higher demands for lubrication and non-flammability, inverse emulations have not been used for multiuse aerosol lubricants.

BRIEF SUMMARY OF THE INVENTION

This invention has found surprisingly that when an invert emulsion made with a synthetic ester base oil and a compatible invert emulsifier is delivered through an aerosol apparatus that creates certain larger than standard droplets it creates a non-flammable multiuse lubricant aerosol. A preservative is included in the composition to prevent the growth of bacteria, yeast, and molds that would interfere with the creation and stability of the emulsion.

The improved water-in-oil aerosol non-flammable multiuse lubricating composition appears to be an improvement over the prior art lubricating compositions because of its improved combination of lubrication, corrosion and rust prevention, water displacement, and fire resistance.

Broadly, the improved multiuse composition is in the form of a substantially stable water-in-oil emulsion consisting of 10% to 20% by weight of a liquified, normally gaseous, propellant and 80% to 90% of a base consisting essentially of by weight:

A. 45% to 55% of water;

B. 5% to 10% water-in-oil emulsifier compatible with a synthetic ester base oil;

C. 35% to 45% of synthetic ester base oil; and

D. 0.01% to 1% of preservative.

Also, within the scope of the claimed invention is the aerosol apparatus for delivering the formulation in a stable non-flammable form. Aerosols of the current invention created using a standard stem sizes, however, are flammable. The current invention uses stems and actuators with increased radiuses or other components to create larger droplets in the aerosol, which in turn creates a non-flammable aerosol. Using standard aerosol components, a stem orifice of 0.013″ to 0.025″ is preferable.

DETAILED DESCRIPTION OF THE INVENTION

A multiuse composition in the form of a substantially stable water-in-oil emulsion consists of 13% Honeywell's Solstice (HFO-1234ze) propellent by weight and 87% to a base consisting essentially of by weight:

A. 51.95% of deionized water;

B. 8% Hypermer 2524;

C. 40% of Priolube LL-564; and

D. 0.05% of Reputain B-30.

The aerosol apparatus for delivering the formulation in a stable non-flammable form consists of standard aerosol components with a stem with increased orifice of 0.020″ and two entry ways for uptake of the base liquid.

Hypermer 2524 is an oligomeric ester emulsifier for use in the manufacture of inverse polymer emulsions. It is compatible with synthetic esters such as Priolube LL-564 as an inverse emulsifier. It is a proprietary product manufactured and sold by Croda International Plc.

Priolube LL-564 is a low viscosity synthetic ester. It is a proprietary product manufactured and sold by Croda International Plc.

Reputain B-30 is a preservative that contains 2-bromo-2-nitropropane-1,3-diol (30%), Propylene glycol (57.5-62.5%), and Water (7-10%).

The above composition has shown surprisingly good lubricating and anticorrosion properties while maintaining non-flammability in both the liquid and aerosol form.

Comparative Testing

The invert emulsion was the only formulation that had lubricating and anticorrosion properties similar to the market leader WD-40®, while remaining non-flammable in both liquid and aerosol form.

Alternative formulas tested included oil-in-water emulsions, chlorinated hydrocarbons and perfluoropolyether (PFPE), and phosphate esters, phosphate ester and fluorinated hydrocarbons. Those formulas included:

Synthetic Emulsion—This is a proprietary synthetic metal working fluid formulation provided by Croda International Plc. Semisynthetic Emulsion—This is a proprietary semisynthetic metal working fluid formulation provided by Croda International Plc. GPL and PFPE—This is a formulation of chlorinated hydrocarbons and perfluoropolyether (PFPE). It consists of 83.3% Vertrel XF (Chlorinated hydrocarbon), 14.7% Acetone, and 2% GPL-105 (PFPE). Vertel XF (1,1,1,2,2,3,4,5,5,5-Decafluoropentane) is a proprietary hydrofluorocarbon fluid used as a solvent and vapor degreasing equipment for cleaning, rinsing, and drying. Vertel XF is supplied by Chemours. GPL-105 is a clear, colorless perfluoropolyether oil that is nonflammable and long-lasting. On a weight basis, GPL-105 contains 21.6% carbon, 9.4% oxygen, and 69.0% Fluorine. It is sourced from Chemours. KDP and PFPE—This is also a formulation of chlorinated hydrocarbons and perfluoropolyether (PFPE). It consists of 83.3% Vertrel XF (Chlorinated hydrocarbon), 14.7% Acetone, and 2% KDP (PFPE). KDP is the same as GPL, but also contains anti-corrosion additive. It is sourced from Chemours. Phosphate Ester—This is a product sold by Exxon under the name Hyjet V. It is marketed as a fire-resistant hydraulic fluid based on phosphate esters. Its chemical composition is commercially described as 70-80% tributyl phosphate, 10-20% phenol, isopropylated, phosphate, 5-7% aliphatic epoxide, and 0.1-1% 2,6-Di-Tert-Butyl-P-Cresol. Phosphate Ester and Fluorinated Hydrocarbons—It contains 65% Reolube and 35% Vertel XF. Reolube 46B is sold by Chemours and marketed as a fire-resistant hydraulic fluid. It is essentially 100% Phenol, isobutylenated, phosphate, with less than 25% of phenols triphenyl phosphates.

Below is a comparison of the preferred embodiment to the other prospective multiuse lubricants and WD-40®.

Lubrication Testing:

The invert emulsion was generally comparable or better than most of the other potential non-flammable multiuse lubricators. Three tests were performed on the formulations to determine their relative abilities to lubricate under varying conditions. Those tests and results are described below.

ASTM D-4172: Wear Preventive Characteristics for Lubricating Fluid.

This test is commonly known as the Four Ball Wear and measures the wear protection of a test fluid. Three steel balls are clamped together and covered with the lubricant to be evaluated. A fourth steel ball is pressed with force into the top cavity formed by the three lower balls. The temperature of the test lubricant can be regulated and then the top ball is rotated at 1200 rpm for 60 minutes. Lubricants are compared by the average of the measure (in mm) of the scar worn into the three lower balls. Good results are less than 1.0 mm with excellent results being around 0.5 mm. Anti-wear fluids will reduce the amount of metal lose due to friction during a metalworking process or metal to metal contact.

ASTM D-3233: Measurement of Extreme Pressure Properties of Fluid Lubricants (Falex Pin and Vee Block Methods).

This test measures the load-carrying properties of a lubricant by rotating a steel pin at 290 rpm against two stationary V-blocks immersed in the lubricant sample. Load, in 250 foot pound increments, is applied to the V-blocks by a ratchet mechanism. The load is increased every minute until failure occurs as indicated by breakage of the shear pin or test pin, or inability to increase or maintain the load on the ratchet wheel. Results are reported as pounds with 4,500 being the maximum that can be detected. An extreme pressure fluid will maintain its lubricating properties as pressure and temperature increases.

ASTM D-5620: Evaluating Thin Film Fluid Lubricants in a Drain and Dry Mode.

This tests measures the endurance or wear life of a lubricant. The test fluid is deposited on the pin and V-blocks and allowed to drain for 1 to 4 minutes. The steel pin is rotated at 290 rpm against two stationary V-blocks and a load of 300 foot pounds is applied. If after 60 minutes, there is no failure, the load is increased to 500 foot pounds. Failure is when the steady state torque is interrupted by a sharp increase or spike in the torque, breakage of the shear pin, or failure to maintain the load. Results are reported in minutes at load pounds.

TABLE 1 Formulation ASTM D-4172 ASTM D-3233 ASTM D-5620 Invert Emulsion 0.60 mm 3789 lbs 20.5 min WD-40 ® 0.60-0.70 mm 1300-2000 lbs 1-10 min Synthetic Emulsion 0.75 mm 3901 lbs 0.14 min Semisynthetic 0.84 mm 4500+ lbs 0.32 min Emulsion GPL and PFPE 0.95 mm 1350 lbs 7.5 min KDP and PFPE 2.24 mm 1550 lbs 1.50 min Phosphate Ester 0.62 mm 1900 lbs 5.5 min Phosphate Ester 0.59 mm 4500+ lbs 14.7 min and Fluorinated Hydrocarbons

Anticorrosion Testing:

The invert emulsion was markedly better than most of the other potential non-flammable multiuse lubricators. Two tests were performed on the formulations to determine their relative abilities to prevent corrosion and rust. Those tests and results are described below.

ASTM B-117: Salt Spray (Fog) Apparatus.

This test is used to measure the level of corrosion protection provided by a test fluid. Cold rolled steel panels, with surface prepared by sand blasting, are treated with the fluid by dipping or spray, allowed to drain for 2 hours, then placed in the salt spray cabinet that contains a fog of 5% salt (NaCl) water solution at 35° C. (95° F.). Panels are left in the closed cabinet for the entire test period; we typically use a 72 hour period.

FTM-3007: Water Displacement.

This test is used to measure the ability of a fluid to displace water on a metal surface and then provide corrosion protection. Cold rolled steel panels, with surface prepared by sand blasting, are immersed in deionized water and then immersed in the test fluid just prior to being place in a static humidity chamber (25° C. and 50% humidity) for one hour. The procedure is repeated but using the test fluid after a 10% level of water has been added and mixed with it. Results are reported as % visible corrosion for both the as is and the contaminated fluid.

TABLE 2 Formulation ASTM B-117 FTM-3007 Invert Emulsion No Rust at 72 Hours No Corrosion on Both WD-40 ® 0-20% Rust at72 hours No Corrosion on Both Synthetic Emulsion 87% Rust at 24 Hours No Corrosion on Both Semisynthetic 87% Rust at 24 Hours No Corrosion on Both Emulsion GPL and PFPE 90% Rust at 24 hours Original: 0-1% corrosion. Contaminated: 1-3% corrosion KDP and PFPE 95% Rust at 24 hours Original: 25-50% corrosion. Contaminated: 85-97% corrosion. Phosphate Ester 90% Rust at 24 hours Original: 2-5% corrosion. Contaminated: 2% corrosion Phosphate Ester 95% Rust at 24 Hours Original: 40% corrosion. and Fluorinated Contaminated: 45% Hydrocarbons corrosion

Flammability Testing:

The invert emulsion was the only potential non-flammable multiuse lubricant with superior lubrication and anticorrosion properties that was also non-flammable in an aerosol form. The Invert Emulsion was tested for flammability using a straw connected the actuator and without. Three tests were performed on the formulations to determine their relative flammability profile. Using the larger stem orifice radius reduced the flammability profile of the invert emulsion. Those tests and results are described below.

Flame Extension and Flashback (Outlined in CFR Part 16 1500.45)

A spray can is placed in a holding device 15 cm from an open flame source set at a height of 5 cm. The spray can is discharged for 5 seconds and the flame extension is measured. The operator can then determine if a flashback exists by observing if a flame travels backwards toward the spray can.

GHS UN Ignition Distance (Performed per UNECE Part III 31.4)

A spray can is discharged towards an open flame starting at a distance of 60 cm. The distance is shortened incrementally until a sustained ignition is observed.

Enclosed Space Ignition (Performed per UNECE Part III Section 31.5)

A spray can is discharged into a test vessel (55 gallon drum) containing a burning candle. A timer is started at the time the can was discharged in order to determine the time elapsed before ignition, if any.

TABLE 3 GHS UN Enclosed Flame Extension Ignition Space Formulation and Flashback Distance Ignition Invert Emulsion 18 inch flame (no 30 cm (no straw) >300 s/m3 (Standard Aersol straw) <15 cm (with with 0.013 Stem) No flame (with straw) straw) No flashback Invert Emulsion No flame extension No flame >300 s/m3 (Aersol with No flashback 0.02″ Stem) WD-40 ® Produces a flame Greater than <300 s/m3 extension and 15 cm flame flashback Synthetic Emulsion No flame extension No flame >300 s/m3 No flashback Semisynthetic No flame extension No flame >300 s/m3 Emulsion No flashback GPL and PFPE No flame extension No flame >300 s/m3 No flashback KDP and PFPE No flame extension No flame >300 s/m3 No flashback Phosphate Ester No flame extension No flame >300 s/m3 No flashback Phosphate Ester No flame extension No flame >300 s/m3 and Fluorinated No flashback Hydrocarbons

While only a limited number of preferred embodiments of the present invention have been disclosed for purposes of illustration, it is obvious that many modifications and variations could be made thereto. It is intended to cover all of those modifications and variations which fall within the scope of the present invention, as defined by the following claims. 

We claim:
 1. An aerosol lubricating composition comprising by weight: 45% to 55% of water; 5% to 10% water-in-oil emulsifier compatible with a synthetic ester base oil; 35% to 45% of synthetic ester base oil; and a preservative.
 2. The composition of claim 1 in which the water-in-oil emulsifier is an oligomeric ester emulsifier.
 3. The composition of claim 2 in which the water-in-oil emulsifier is Hypermer
 2524. 4. The composition of claim 1 in which the base oil is a low viscosity synthetic ester.
 5. The composition of claim 4 in which the base oil is Priolube LL-564.
 6. The composition of claim 1 in which the preservative is Reputain B-30.
 7. The composition of claim 1 in which the water is deionized.
 8. The composition of claim 1 in which the composition is provided in an aerosol delivery mechanism with a stem and actuator of sufficient width radius to a create non-flammable mist.
 9. The composition of claim 8 in which the stem width radius is between 0.013″ to 0.025″.
 10. The composition of claim 9 in which the stem width radius is 0.020″.
 11. The composition of claim 1 in which the composition is mixed with a non-flammable propellent in a ratio of 10% to 20% propellent and 80% to 90% composition.
 12. The composition of claim 11 in which the composition is mixed with a non-flammable propellent in a ratio of 13% propellent and 87% composition.
 13. The composition of claim 11 in which the propellent is Honeywell's Solstice (HFO-1234ze).
 14. An aerosol lubricating composition comprising by weight: 95% of deionized water; 8% Hypermer 2524; 40% of Priolube LL-564; and 0.05% of Reputain B-30.
 15. The composition of claim 14 in which the composition is provided in an aerosol delivery mechanism with a stem and actuator of sufficient width radius to a create non-flammable mist.
 16. The composition of claim 15 in which the stem width radius is between 0.013″ to 0.025″.
 17. The composition of claim 16 in which the stem width radius is 0.020″.
 18. The composition of claim 14 in which the composition is mixed with a non-flammable propellent in a ratio of 10% to 20% propellent and 80% to 90% composition.
 19. The composition of claim 15 in which the composition is mixed with a non-flammable propellent in a ratio of 13% propellent and 87% composition.
 20. The composition of claim 18 in which the propellent is Honeywell's Solstice (HFO-1234ze). 